Polyurethane foam and methods of forming the same
AssigneeSaint-Gobain Performance Plastics Corporation
InventorsWenjun Sun, Yue Dong
Life of this patent
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Abstract
The subject application relates to polyurethane foam and methods of forming the same. A polyurethane foam may include a polyurethane foam may include a first polyol component, a second polyol component, and a third polyol component. The first polyol component may include at least one component selected from the group of a polyether polyol and a polyester polyol. The second polyol component may include a polyether polyol. The third polyol component may include a grafted polyether polyol. The polyurethane foam may have a density of at least about 100 kg/m3 and not greater than about 800 kg/m3. The polyurethane foam may have an adjusted compression force deflection to density ratio of at least about 0.3.
Claims19
A polyurethane foam prepared from a reaction mixture, wherein the reaction mixture comprises:
- a first polyol component having a molecular mass of at least about 2000 g/mol and not greater than about 5800 g/mol, and comprising at least one component selected from the group of a polyether polyol and a polyester polyol,
- a second polyol component comprising a polyether polyol,
- a third polyol component comprising a grafted polyether polyol,
- wherein the reaction mixture comprises the first polyol component in an amount of at least about 5 wt. % and not greater than about 50 wt. % for a total weight of the reaction mixture,
- wherein the reaction mixture comprises the second polyol component in an amount of at least about 7 wt. % for a total weight of the reaction mixture,
- wherein the reaction mixture comprises the third polyol component in an amount of at least about 1 wt. % and not greater than about 45 wt. % for a total weight of the reaction mixture,
- wherein the polyurethane foam has a glass transition temperature of at least about 10° C.,
- wherein the polyurethane foam has a density of at least about 175 kg/m3 and not greater than about 800 kg/m3, and
- wherein the polyurethane foam has an adjusted compression force deflection to density ratio of at least about 0.3, where the adjusted compression force deflection to density ratio is equal to CFD70/(D{circumflex over ( )}2.6), where the CFD70 is equal to the compression force deflection of the polyurethane foam in Pa measured at 23° C., 70% compressive strain, and D is equal to the density of the polyurethane foam in kg/m3.
A method of forming a polyurethane foam comprising:
- providing a raw material mixture comprising:
- a raw first polyol component having a molecular mass of at least about 2000 g/mol and not greater than about 5800 g/mol, and comprising at least one component selected from the group of a polyether polyol and a polyester polyol,
- a raw second polyol component comprising a polyether polyol,
- a raw third polyol component comprising a grafted polyether polyol,
- a raw fourth polyol component comprising a polycaprolactone polyol;
- and
- forming the raw material mixture into a polyurethane foam,
- wherein the polyurethane foam comprises the raw first polyol component in an amount of at least about 5 wt. % and not greater than about 50 wt. % for a total weight of the raw material mixture,
- wherein the polyurethane foam comprises the raw second polyol component in an amount of at least about 7 wt. % for a total weight of the raw material mixture,
- wherein the polyurethane foam comprises the raw third polyol component in an amount of at least about 1 wt. % and not greater than about 45 wt. % for a total weight of the raw material mixture,
- wherein the polyurethane foam has a glass transition temperature of at least about 10° C.,
- wherein the polyurethane foam has a density of at least about 175 kg/m3 and not greater than about 800 kg/m3, and
- wherein the polyurethane foam has an adjusted compression force deflection to density ratio of at least about 0.3, where the adjusted compression force deflection to density ratio is equal to CFD70/(D{circumflex over ( )}2.6), where the CFD70 is equal to the compression force deflection of the polyurethane foam in Pa measured at 23° C., 70% compressive strain, and D is equal to the density of the polyurethane foam in kg/m3.
Dependencies are inferred from the claim text.